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TE Connectivity Ocean 1.0 Instruction Sheet

End-feed applicators
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1. INTRODUCTION
Ocean 1.0 end-feed applicators are available with a mechanical feed, air feed, or servo feed system. Each
applicator accepts the end-feed strip-form of terminals identified on the applicator parts list and exploded view
drawing (applicator log) to apply to pre-stripped wires.
NOTE
Dimensions in this instruction sheet are in millimeters with [inches in brackets]. Figures are for reference only and are not
drawn to scale.
This instruction sheet, along with the parts list, exploded-view drawing (packaged with applicator), and
applicable terminating machine manual (Table 1), provide all the information required to operate and maintain
the applicator and machine.
NOTE
Refer to instruction sheet
© 2022 TE Connectivity Ltd. family of companies.
All Rights Reserved.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
Ocean 1.0 End-Feed Applicators
Figure 1: Ocean 1.0 end-feed applicators
Table 1: Terminating machine manuals
Manual
Machine
409-5128
Basic AMP-O-LECTRIC™
409-5207
Model T
409-5289
409-5842
Model G
AMP 3K™ 1725950-[ ]
409-10047
AMP 5K™ 1725900-[ ]
AMP 3K/40™ 2119683-[ ]
409-10099
AMP 5K/40™ 2119684-[ ]
408-35005
for translations of the Safety Warnings specified herein.
PRODUCT INFORMATION 1-800-522-6752
408-10390
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Instruction Sheet
17 AUG 2022 Rev T
1 of 25

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Summary of Contents for TE Connectivity Ocean 1.0

  • Page 1 1 of 25 For latest revision and Regional Customer Service, All Rights Reserved. visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
  • Page 2 408-10390 2. DESCRIPTION Figure 2 shows the main components of the mechanical feed applicator. Figure 3 shows the main components of the air feed applicator. Each applicator is individually designed for specific terminals. The wire crimp height and insulation crimp height can be adjusted to accommodate different wire sizes and insulation ranges.
  • Page 3 408-10390 Figure 3: Air-feed applicator 1 Air feed cam Mounting screw (2 places) Feed backstroke adjustment knob 2 Air supply connection Feed stroke adjustment knob Detent screw (2 places) 3 Retract speed control End cap Feed arm 4 Forward speed control End cap bolt (2 places) Feed pawl The feeder assembly can be removed from the applicator and replaced with any different style (mechanical, air,...
  • Page 4 408-10390 The Ocean applicator can be used in various machines, provided the machine has the proper stroke length and all the necessary equipment. Two basic applicator design styles (Atlantic and Pacific) are available to meet many of the terminator and leadmaker configurations worldwide (Figure 5). The applicator ram and base plate interfaces are different, but most of the Ocean applicator features and adjustments are the same.
  • Page 5 408-10390 2.1. Applicator with mechanical feed system With this applicator (Figure 6), the terminals are fed by the action of the feed cam and a series of rods and levers that move the feed pawl. Figure 6: Applicator with mechanical feed system 1 Feed mounting screw (2 places) Stock drag adjustment nuts Feed pawl adjustment screw...
  • Page 6 408-10390 These feed cams can be mounted in two different mounting holes, depending on machine stroke length and feed type (Figure 8 and Figure 9). When not in use, the spare feed cam can be mounted to the applicator housing in the spare feed cam storage location (Figure 6). Figure 8: Mounting a feed cam on 40-mm [1⅝-in.] stroke machine 1 Mechanical pre-feed cam 2 Mechanical post-feed cam...
  • Page 7 408-10390 2.2. Applicator with air feed system With an air feed applicator (Figure 3), the terminals are fed by the action of an air feed module using a constant air supply that moves the feed pawl. The exhaust control valves control the speed of the feed and retract strokes.
  • Page 8 2.3. Applicator with servo feed system With this applicator, the wire crimp height and terminal feed are accomplished by the AMP-O-LECTRIC III servo terminator or any machine that incorporates the TE Connectivity precision controller. Refer to 409-10073. NOTE Some applicators do not work with the standard feed pawl in the feeder. In these cases, a special feed pawl must be used. If originally ordered with the servo feed, the applicator is shipped with the special feed pawl already mounted.
  • Page 9 408-10390 2.6. Applicator with Pacific head The Pacific applicator works only if the machine’s ram falls within the envelope shown in Figure 11. (Dimensions are in millimeters, with inches in brackets.) Figure 11: Ram dimensions for use with Pacific applicator 3.
  • Page 10 408-10390 3.1. AMP-O-LECTRIC and Model K machines (with mini-applicator conversion) Installation This machine must be equipped with machine conversion kit PN 690675-2 to adapt it for use with miniature applicators. The kit includes applicator instruction sheet 408-8022, which explains how to install and remove an applicator with a mechanical feed.
  • Page 11 408-10390 4. LOADING AND UNLOADING THE APPLICATOR Some terminal strips require the use of a terminal lubricant to reduce tooling wear and help reduce damage to the plating on some terminals. Wick-type lubricators apply lubricant to the terminal strip as it feeds into the applicator.
  • Page 12 408-10390 5. ADJUSTMENTS 5.1. Adjusting the wire crimp 1. Select an increment number from 0 (largest crimp height) to 150 (smallest crimp height) from the data plate for the wire size to be used. Each increment represents a change in crimp height of 0.01 mm [.0004 in.].
  • Page 13 408-10390 5.2. Adjusting the insulation crimp The insulation crimp is adjustable in increments of 0.19 mm [.0075 in.] by pulling the insulation crimp dial out (refer to Figure 5) and turning it to line up with the number (1 through 18) so that it is shown at the indicator notch on the ram: Number 1 makes the loosest crimp and number 18 makes the tightest crimp.
  • Page 14 408-10390 4. If the slug blade does not shear the terminal in the correct position, make note of the position and continue to cycle the applicator to check the backstroke position. If the lead terminal is not slugged out correctly and the backstroke position is incorrect, both the stroke length and the fine feed position must be adjusted.
  • Page 15 408-10390 Adjusting the feed stroke The feed stroke is adjustable in a range of 0 to 49.8 mm, depending on the air feed part number, in stepped increments of 0.04 mm [.0016 in.] for the feed forward position and in 0.08-mm [.0031-in.] increments for the rear feed pawl position (backstroke).
  • Page 16 408-10390 h. Cycle the machine back to top-dead-center, causing the feed to shift forward and feeding the terminal over the anvil. Repeat substeps d through h until the terminal is centered over the slug blade. Adjusting the feed speed The feed mechanism has been adjusted at the factory to ensure that the terminal is advanced at the lowest possible speed.
  • Page 17 408-10390 Servo feed applicator 1. With the terminal strip properly loaded, check the position of the lead terminal over the anvil by actuating the feeder to move the feed pawl to the extend position. The slug blade must remove the connecting tab between the lead and second terminals without deforming either terminal.
  • Page 18 408-10390 5.5. Adjusting the strip guide Disconnect electrical power when performing maintenance or repair on this equipment. 1. Turn off the machine. 2. Disconnect the power cord. 3. Raise the ram. 4. Remove the applicator from the machine as described in section 3, INSTALLING AND REMOVING THE APPLICATOR.

  • Page 19: Replacement And Repair

    408-10390 10. Securely tighten the four rearmost screws. The strip should slide easily between the guides with a minimum of clearance. 11. If present, adjust the strip hold-down plate (Figure 14) so that it is square with the terminal strip. Position it so that it does not interfere with the slug blade tooling on the ram (Figure 5).
  • Page 20 408-10390 6. Check the worn shear plates to determine whether they can be reoriented to provide another usable shearing edge.  Most rear plates are the same at the front and rear. If so, and if the second side is not worn, turn the plate front to the rear, making sure that the widest part of the chip clearance groove is at the bottom.
  • Page 21 408-10390 11. Slowly hand-cycle the machine while watching alignment of the crimpers with the anvil. 12. When the ram assembly reaches the bottom of the stroke, carefully tighten the crimper bolt to a torque between 10.8 and 13.6 Nm [8 and 10 ft-lb]. The crimpers must move without interference over the anvil after the heavy paper is removed.
  • Page 22 408-10390 6.8. Repairing the adjustable crimp height Under some severe operating conditions or applications, the crimp height shim can break or become dislodged. This can cause the applicator to produce terminations with a different crimp height than specified. To correct this problem, complete the following steps.
  • Page 23 408-10390 3. Remove the single revolution limiter bolt (Figure 16). 4. Hold the ram assembly with the ram post (or clamp, depending on the applicator style) pointing up. 5. Unscrew the ram post (or clamp) from the ram, exposing the adjustment screw assembly. If necessary, place the ram in a soft-jaw vise to free both hands for turning the ram post (or clamp).
  • Page 24 408-10390 6.9. Wire depressor accessory If this accessory was not installed on the applicator at the factory, use Figure 17 to identify the parts you need in order to add it. NOTE To add a wire depressor to an existing applicator, the existing crimper spacer must be at least 0.64 mm [.025 in.] thick. Figure 17: Wire depressor accessory parts 1 Existing crimper spacer 2 Replacement crimper spacer...

  • Page 25: Cleaning, Lubrication, And Storage

    408-10390 2. Use Table 3Error! Reference source not found. to determine which crimper spacers you need to achieve the required thickness. Table 3: Crimper spacers, by thickness Thickness Crimper spacer Thickness Crimper spacer Thickness Crimper spacer mm [in.] part number mm [in.] part number mm [in.]...